There is no universal size ratio that works for every group. A workplace with a required uniform, a youth event, and a public-facing festival all need different planning. The dependable method is to count known sizes first, keep unknowns visible, and choose a small buffer intentionally.
Start with known sizes, not a generic chart
Send a size form, roster, or RSVP question before you order. Separate confirmed sizes from estimates. If the order is for a team or staff group, a complete size list is usually more valuable than a larger quantity of guesswork.
Build the estimate for the unknown portion
For the people who have not responded, use the sizes already collected as your best local signal. If the first responses cluster around a few sizes, keep that shape instead of forcing a national “average.” Add flexibility where it is most likely to be useful: common middle sizes, rather than one of every size.
Decide on a buffer before you place the order
A buffer protects against late additions, exchanges, and volunteers who appear after the list closes. It is not a substitute for a roster. Choose the buffer based on the cost of running short, whether extras can be used later, and whether the garments are event-specific.
Use this quote-ready checklist
- Total quantity and confirmed size count
- Estimated size mix for unconfirmed people
- Garment style and color
- Decoration locations and artwork
- Need-by date and any planned buffer
Once the size run is settled, compare the decoration method with the quantity. Screen printing often fits repeatable group orders, while DTF printing can be useful when artwork or quantities are more varied.
Frequently asked question
Should I order extra shirts in every size?
Usually not. Put extras where the response list suggests they are most likely to be needed. For a small, named group, it may be better to wait for confirmations than to spread a tiny buffer across every size.